Cap-installation signal system for filler neck cap

ABSTRACT

A filler neck cap is adapted to mate with and close a filler neck. The filler neck cap includes a closure configured to engage the filler neck, an outer handle configured to be gripped by a consumer, and a torque-transmission member configured to transmit torque applied to the outer handle by the consumer to the closure to rotate the closure relative to the filler neck during installation of the cap in the filler neck and removal of the cap from the filler neck.

PRIORITY CLAIM

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Application Ser. No. 61,489,943, filed May 25, 2011 and Ser.No. 61/568,511, filed Dec. 8, 2011, which are expressly incorporated byreference herein.

BACKGROUND

The present disclosure relates to filler neck caps, and particularly toa rotatable cap for closing the open mouth of a filler neck. Moreparticularly, the present disclosure relates to a filler neck closurecap designed to provide a cap-installation signal to a user to alert theuser that the cap is installed in the filler neck.

SUMMARY

According to the present disclosure, a filler neck cap includes a handleand a closure adapted to mate with a fuel tank filler neck and close amouth opening into a nozzle-receiving passageway formed in the fillerneck. A cap installer mounts the filler neck cap on the filler neck byapplying a torque to the handle to turn the cap about an axis ofrotation to rotate the closure until the closure arrives at a stationaryfiller-neck closing position in the filler neck. Upon removal of the capfrom the filler neck, a fuel-dispensing nozzle can be inserted into thenozzle-receiving passageway formed in the fuel tank filler neck throughthe open mouth to deliver fuel to the fuel tank.

In illustrative embodiments, the filler neck cap includes a closureconfigured to mate with the filler neck and close an aperture openinginto a fuel-conducting passageway formed in the filler neck. The fillerneck cap also includes a rotatable outer handle and atorque-transmission member arranged to lie under the outer handle androtate in a cap-advancing (clockwise) direction with the outer handleduring installation of the filler neck cap in the filler neck.

In illustrative embodiments, the torque-transmission member isconfigured to include a circular hub and a deflectable closure rotatorcantilevered to the circular hub. There are four deflectable closurerotators coupled to the circular hub and arranged to lie generally inNORTH, EAST, SOUTH, and WEST positions relative to the circular hub.

In illustrative embodiments, during installation of a filler neck cap ina filler neck, a cap installer grips and turns the outer handle about anaxis of rotation to cause the torque-transmission member and itsdeflectable closure rotator to rotate about the axis of rotation. Thedeflectable closure rotator (1) applies torque to rotate the closure inthe filler neck until the closure arrives at a stationary closurehard-stop position in the filler neck and (2) generates a discernablewarning signal to alert the cap installer that the filler neck cap hasbeen installed in the filler neck during continued rotation of the outerhandle relative to the closure until the outer handle finally arrives ata stationary handle hard-stop position.

In an illustrative embodiment, the deflectable closure rotator isarranged to engage torque teeth included in a torque receiver providedin the closure normally to transmit torque from the torque-transmissionmember to the closure during installation of the cap in the filler neckto cause the closure to rotate in the filler neck in response toclockwise rotation of the outer handle relative to the filler neck. Thedeflectable closure rotator and the torque teeth also cooperate todefine a cap-installation signaler that generates a discernable warningsignal to alert a cap installer that the closure has already arrived ata stationary filler neck-closing position and that continued rotation ofthe outer handle is unnecessary.

In accordance with the present disclosure, a fuel cap designer canconfigure the filler neck cap to produce at most a predetermined numberof discernable warning signals by providing a like number of torqueteeth that are arranged to be engaged by the deflectable closure rotatorafter the closure arrives at the stationary closure hard-strip positionin the filler neck and before the outer handle arrives at the stationaryhandle hard-stop position. These signal-generating torque teeth arelocated in series in a signal-generation zone provided on the closureand located between an anti-rotation stop included in the closure and arotation-inhibitor tab included in the outer handle when the outerhandle is rotated by a torsion spring relative to the closure to assurea ready-to-install initial position.

The torque teeth are arranged to lie in the signal-generation zone atthe start of a cap-installation activity and to intercept the rotatingdeflectable closure rotator. A discernable warning signal (e.g.,clicking sound or tactile sensation) is produced each time thedeflectable closure rotator engages and then disengages one of thetorque teeth. For example, only one warning signal will be provided ifthe fuel cap designer provides only one torque tooth in thesignal-generation zone. In contrast, a series of three warning signalscould be generated if the fuel cap designer provides a series of threetorque teeth in the signal-generation zone.

In illustrative embodiments, after the closure has arrived at astationary filler-neck closing (hard stop) position and during continuedclockwise rotation of the outer handle relative to the stationaryclosure in the latter stage of a cap-installation activity, a radiallyoutwardly extending drive head carried on an elastic spring arm of thedeflectable closure rotator is moved over and past each of the radiallyinwardly extending torque teeth included in the closure and provided ina signal-generation zone to produce the discernable warning signal. Sucha signal is provided to alert a person installing the filler neck capthat the cap has already arrived at the filler neck-closing position andthat continued rotation of the outer handle relative to the filler neckis not needed. In an illustrative embodiment, a clicking sound and atactile sensation is provided each time the head is moved over and pastone of the torque teeth provided in the signal-generation zone.

A torsion spring is coupled to the outer handle and to the closure andarranged to extend through a central aperture formed in thetorque-transmission member in illustrative embodiments of the presentdisclosure. The torsion spring is configured to provide handle-resetmeans for automatically rotating the closure about the axis of rotationrelative to the outer handle in a cap-removal direction while a user isgripping the outer handle as soon as the base of the closure isseparated from the filler neck during a cap-removal activity to cause ahandle-locator stop that is coupled to the closure to rotate therewithto move to engage a handle-locator tab that is coupled to the outerhandle to rotate therewith so that further rotation of the closurerelative to the outer handle is blocked and the closure is ready to beinstalled in a filler neck and the signal-generating torque teeth areonce again located in the signal-generation zone to be engaged by thedeflectable closure rotator during reinstallation of the filler neck capin the filler neck.

Additional features of the present disclosure will become apparent tothose skilled in the art upon consideration of illustrative embodimentsexemplifying the best mode of carrying out the disclosure as presentlyperceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figuresin which:

FIG. 1 is a perspective view of a filler neck in accordance with thepresent disclosure prior to insertion of the cap into the mouth of anunderlying fuel tank filler neck, with portions of an outer handleincluded in the filler neck cap broken away to show an upper portion ofa closure configured to mate with the filler neck and close the openmouth of the filler neck and provided with a torque receiver comprisinga ring of radially inwardly extending torque teeth along a circularouter edge of the closure and just under the outer handle, a torsionspring arranged to wind about an axis of rotation of the rotatable outerhandle and include a lower end coupled to an underlying torsion springretainer and an upper end adapted to be coupled to the underside of theouter handle to provide handle-reset means, and a torque-transmissionmember centered above the torsion spring retainer and provided with fourdeflectable closure rotators (two visible) and arranged on top of theclosure to cause each of the deflectable closure rotators to engage theradially inwardly extending torque teeth included in the closure firstto transmit torque from the handle to the closure during installation ofthe filler neck cap in the filler neck as suggested in FIGS. 6 and 7 andthen to snap past one or more torque teeth provided in asignal-generation zone to generate a series of first, second, and thirddiscernable warning signals (represented diagrammatically by THUNDERBOLTsymbols) to alert a cap installer that the closure has already arrivedat a filler-neck closing position in the filler neck as suggested inFIGS. 8, 10, and 12;

FIG. 2 is an exploded perspective assembly view of a filler neck cap inaccordance with a first embodiment of the present disclosure and apartial perspective view of a companion fuel tank filler neck showingthat the filler neck cap includes (from top to bottom) an outer handle,a handle tether unit including a tether ring and a tether strap coupledto the tether ring, a torsion spring, a torque-transmission memberincluding a hub and four radially outwardly extending deflectableclosure rotators cantilevered to an outer portion of the hub, a torsionspring retainer included in a filler-neck closure, a pressure-reliefsystem comprising a cover plate, a pressure-relief spring, a seal plate,and a sealing gasket, and a vacuum-relief system comprising avacuum-relief valve and a vacuum-relief spring base included in thefiller-neck closure sized to receive the pressure/vacuum-relief systemsin a central cavity formed therein and carry a ring of radially inwardlyextending torque teeth also included in the filler-neck closure andarranged to mate with the four deflectable closure rotators included inthe torque-transmission member, and an O-ring seal sized to mount on anexterior portion of the closure;

FIG. 2A is an enlarged top plan view of the torque-transmission membershown in FIGS. 1 and 2 showing that the torque-transmission memberincludes a circular hub, four deflectable closure rotators coupled to anouter portion of the circular hub and adapted to mate with companiontorque teeth included in the closure, and two deflectable ratchet armscoupled to an inner portion of the circular hub and adapted to mate withcompanion torque teeth included in the outer handle to transmit torquethat has been applied by a cap installer to the outer handle from theouter handle to the torque-transmission member,

FIG. 2B is an enlarged top plan view of the closure shown in FIGS. 1 and2 showing that a perimeter portion of the closure includes a ring ofradially inwardly extending torque teeth arranged to mate with radiallyoutwardly extending drive heads included in the four deflectable closurerotators of the torque-transmission member shown in FIG. 2A in a mannersuggested in FIG. 3 and shown in FIG. 5;

FIG. 3 is an exploded perspective assembly view of the filler neck capof FIGS. 1 and 2 showing the closure, a torsion spring retainer mountedin a center portion of the closure and surrounded by the ring ofradially inwardly extending torque teeth included in the closure, thetorque-transmission member above the closure, the torsion spring abovethe torque-transmission member, and a closure cover including the outerhandle and the handle tether unit coupled to the outer handle andillustrating the underside of the outer handle to show that the outerhandle is formed to include a smaller ring of radially inwardlyextending torque teeth arranged to mate with radially outwardlyextending heads included in the two curved deflectable ratchet armsarranged to lie inside the circular hub provided in the center of thetorque-transmission member;

FIG. 4 is an enlarged sectional view of the filler neck cap taken alongline 4-4 of FIGS. 1 and 5;

FIG. 5 is an enlarged view of the filler neck cap of FIGS. 1 and 4 witha portion of the outer handle removed to show the torsion spring, theunderlying torsion spring retainer, the smaller ring of radiallyinwardly extending torque teeth included in the outer handle andarranged to surround the two curved deflectable ratchet arms included inthe torque-transmission member, the torque-transmission member with itscircular hub, two ratchet arms, and four closure rotators, the largerring of radially inwardly extending torque teeth included in the closureand arranged to surround the four deflectable closure rotators includedin the torque-transmission member, and an outer annular side wallincluded in the outer handle and arranged to surround the ring of torqueteeth included in the closure, and a handle rotation blocker includingtwo opposing anti-rotation stops coupled to an outer surface of the ringof torque teeth included in the closure and two opposingrotation-inhibitor tabs coupled to an inner surface of the annular sidewall of the outer handle;

FIGS. 6-13 show a series of views of the filler neck cap duringinstallation of the filler neck cap in the filler neck;

FIG. 6 is a top plan view, with portions broken away, of the filler neckcap after it has been rotated in a cap-advancing (clockwise) directionto cause a rotation-inhibitor tab provided in a closure rotation blockerand included in the closure to engage an anti-rotation stop provided inthe closure rotation blocker and included in the filler neck as shown inFIG. 1 to provide a HARD STOP for the closure and block further rotationof the closure in the filler neck so that the closure now occupies astationary position in the filler neck without blocking continuedclockwise rotation of the outer handle relative to the stationaryclosure and showing that the drive head of one of the deflectableclosure rotators engaged an inclined ramp surface provided on one of thetorque teeth included in the stationary closure so as to be able totransmit cap-advancing (clockwise) torque to the closure during capinstallation in the filler neck;

FIG. 7 is a view similar to FIG. 6 with most of the outer handleremoved;

FIG. 8 is a top plan view similar to FIG. 6 showing that the outerhandle has been rotated further in the cap-advancing (clockwise)direction relative to the stationary closure to cause the drive head inthe deflectable closure rotator to snap past a downstream first torquetooth provided in the signal-generation zone to produce a FIRSTdiscernable warning signal such as an audible noise and/or a tactilesensation to alert a cap installer turning the outer handle (a firsttime) that the closure has already seated in the filler neck and arrivedat a stationary filler-neck closing (hard stop) position and thatfurther rotation of the outer handle (though possible) is not needed;

FIG. 9 is a view similar to FIG. 8 with most of the outer handle removedshowing that the drive head of each deflectable closure rotator snapspast a first torque tooth to produce a FIRST discernable warning signalrepresented by a thunderbolt symbol;

FIG. 10 is a top plan view similar to FIG. 8 showing that the outerhandle has been rotated still further in the cap-advancing (clockwise)direction relative to the stationary closure to cause the drive head inthe deflectable closure rotor to snap past a downstream second torquetooth provided in the signal-generation zone to produce a SECONDdiscernible warning signal such as an audible noise and/or a tactilesensation to alert the cap installer turning the outer handle (a secondtime) that the closure has already seated in the filler neck and arrivedat a stationary filler neck closing (hard stop) position;

FIG. 11 is a view similar to FIG. 10 with most of the outer handleremoved showing that the drive head of each deflectable closure rotatorsnaps past a second torque tooth to produce a SECOND discernable warningsignal represented by a thunderbolt symbol;

FIG. 12 is a top plan view similar to FIG. 10 showing that the outerhandle has been rotated even further in the cap-advancing (clockwise)direction relative to the stationary closure to cause the drive head inthe deflectable closure rotator to snap past a downstream third torquetooth provided in the signal-generation zone to produce a THIRDdiscernable warning signal such as an audible noise and/or a tactilesensation to alert the cap installer turning the outer handle (a thirdtime) that the closure has already seated in the filler neck and arrivedat a stationary filler-neck closing position;

FIG. 13 is a view similar to FIG. 12 with most of the outer handleremoved showing that the drive head of each deflectable closure rotatorsnaps past a third torque tooth to produce a THIRD discernable warningsignal represented by a thunderbolt symbol;

FIGS. 14-19 show a series of views of the filler neck cap during removalof the filler neck cap from the filler neck;

FIG. 14 is a top plan view similar to FIG. 12 showing that acounterclockwise torque has been applied to the outer handle to urge thetorque-transmission member to begin to rotate in a counterclockwisedirection to cause a flat driver face on the drive head of thedeflectable closure rotator to mate with a companion flat driven face onthe third torque tooth to prepare the closure to be rotated in acap-removal (counterclockwise) direction relative to the filler neckduring a process of removing the filler neck cap from the filler neck;

FIG. 15 is a view similar to FIG. 14 with most of the outer handleremoved;

FIG. 16 is a top plan view similar to FIG. 14 showing that the closureis turning in the filler neck in response to rotation of the outerhandle in the cap-removal (counterclockwise) direction and applicationof a rotation inducing torque from the deflectable closure rotators tothe torque teeth of the closure;

FIG. 17 is a view similar to FIG. 16 with most of the outer handleremoved;

FIG. 18 is a top plan view similar to FIG. 16 after the filler neck caphas been removed from the filler neck; and

FIG. 19 is a view similar to FIG. 18 with most of the outer handleremoved and showing that the torsion spring (that had been loaded duringthe cap-installation process) was freed and able to unload as soon asthe filler neck cap was removed from the filler neck to reset theposition of the outer handle and its rotation-inhibitor tab so that thefiller neck cap is ready to be reinstalled in a filler neck.

DETAILED DESCRIPTION

A filler neck cap 10 is configured to mate with a filler neck 12 toclose an inlet aperture 12A opening into a fuel-conducting passageway12P formed in filler neck 12 as suggested in FIG. 1. A cap-installationsignaler 11 in accordance with the present disclosure is included infiller neck cap 10 as shown diagrammatically in FIG. 2. Cap-installationsignaler 11 is defined by a deflectable closure rotator 11CR included ina torque-transmission member 18 included in filler neck cap 10 incooperation with radially inwardly extending torque teeth 11T includedin a torque receiver 110 included in closure 14 included in filler neckcap 10. Each torque tooth 11T includes an inclined ramp surface 11TR anda vertical flat surface 11TF as shown, for example, in FIGS. 1, 2, 2B,and 5.

Cap-installation signaler 11 is configured to provide signal means forproducing a discernable warning signal (represented by THUNDERBOLTSYMBOL WS1) to alert a cap installer turning an outer handle 16 includedin filler neck cap 10 in a cap-advancing (e.g., clockwise) direction 22in filler neck 12 about an axis of rotation 20 during installation offiller neck cap 10 in filler neck 12 that closure 14 has seated in afiller-neck closing position in filler neck 12 as suggested in FIGS. 8and 9. The cap installer receiving discernable warning signal WS1 willunderstand that filler neck cap 10 has been installed in filler neck 12and then stop turning outer handle 16 about axis of rotation 20. Two ormore further discernable warning signals WS2, WS3 are contemplated inthe present disclosure as suggested in FIGS. 10-13 before arotation-inhibitor tab 17T1 coupled to outer handle 16 engages ananti-rotation stop 17S1 coupled to stationary closure 14 to provide aHARD STOP and block any further rotation of outer handle 16 incap-advancing (clockwise) direction 22 relative to the stationaryclosure 14 about axis of rotation 20.

In accordance with the present disclosure, a fuel cap designer canpredetermine the maximum number of discernable warning signals that canbe generated after the closure 14 arrives as the closure hard-stopposition as is seated in the filler-neck closing position shown in FIGS.5-7 and before the outer handle 16 is rotated from a ready-to-installinitial position shown in FIG. 5 to a stationary handle hard-stopposition shown in FIGS. 12 and 13 by providing an equal number of torqueteeth 11T in a signal-generation zone 11Z provided between anti-rotationstop 17S1 and rotation-inhibitor tab 17T1 when outer handle 16 lies inthe ready-to-install initial position as suggested in FIG. 5. Assuggested in FIG. 5, three torque teeth 11T1, 11T2, and 11T3 areprovided in signal-generation zone 11Z and this provides for at mostthree discernable warning signals WS1, WS2, and WS3 as suggested inFIGS. 6-13 if outer handle 16 is rotated by a cap installer during acap-installation activity relative to a stationary closure 14 untilrotation-inhibitor tab 17T1 of outer handle 16 engages the stationaryanti-stop tab 17S1 of closure 14.

Filler neck cap 10 includes an outer handle 16 and a closure 14including a base 14B adapted to mate with a fuel tank filler neck 12 andclose a mouth 12A opening into a nozzle-receiving passageway 12P formedin filler neck 12. A cap installer mounts filler neck cap 10 on fillerneck 12 by applying a torque to outer handle 16 to turn cap 10 about anaxis of rotation 20 to rotate closure 14 until closure 14 arrives at astationary filler-neck closing position in filler neck 12. Upon removalof cap 10 from filler neck 12, a fuel-dispensing nozzle can be insertedinto nozzle-receiving passageway 12P formed in fuel tank filler neck 12through the open mouth 12A to deliver fuel to the fuel tank.

A filler-neck closure system in accordance with the present disclosureincludes filler neck cap 10 and a closure-rotation blocker 15 comprisingan anti-rotation stop 15S coupled to filler neck 12 and arotation-inhibitor tab 15T included in closure 14 and coupled to a base14B included in closure 14 of filler neck cap 10 to rotate therewithabout axis of rotation 20 as suggested in FIGS. 1 and 2. Duringinstallation of filler neck cap 10 into filler neck 12, cap 10 will beturned in cap-advancing (clockwise) direction 22 about axis of rotation20 by a cap installer until the outwardly extending rotation-inhibitortab 15T engages the inwardly extending anti-rotation stop 15S to providea HARD STOP for closure 14 and block further rotation of closure 14 infiller neck 12 without, however, blocking continued rotation of outerhandle 16 about axis of rotation 20 in cap-advancing (clockwise)direction 22 relative to the now-stationary closure 14.

A handle-rotation blocker 17 is also included in filler neck cap 10 assuggested in FIGS. 1, 2, and 5. Handle-rotation blocker 17 includes afirst anti-rotation stop 17S1 coupled to base 14B of closure 14 and afirst rotation-inhibitor tab 17T1 coupled to outer handle 16 to rotatetherewith about axis of rotation 20. During installation of filler neckcap 10 into filler neck 12, closure 14 will be rotated about axis ofrotation 20 until it reaches a stationary filler-neck closing positiondetermined by the HARD STOP established by closure-rotation blocker 15.However, outer handle 16 is free to be rotated further in cap-advancing(clockwise) direction by the cap installer as suggested in FIGS. 8-13until the inwardly extending first rotation-inhibitor tab 17T1 engagesthe outwardly extending first anti-rotation stop 17S1 as shown in FIGS.12 and 13 to provide a HARD STOP for outer handle 16 and block furtherrotation of outer handle 16 about axis of rotation 20 in cap-advancing(clockwise) direction 22 relative to closure 14. In an illustrativeembodiment, handle rotation blocker 17 also includes a secondanti-rotation stop 17S2 coupled to closure 14 (to lie in diametricallyopposed relation to first anti-rotation stop 17S1) and a companionsecond rotation-inhibitor tab 17T2 coupled to outer handle 16 (to lie indiametrically opposed relation to first rotation-inhibitor tab 17T1).

Cap-installation signaler 11 functions after closure 14 has reached itsstationary closure hard-stop position and before outer handle 16 reachesits stationary handle hard-stop position to generate a discernablewarning signal (e.g., WS1 shown diagrammatically in FIGS. 8 and 9) toprovide an audible noise and/or a tactile sensation to alert the capinstaller turning outer handle 16 that closure 14 has already seated infiller neck 12 and arrived at a stationary filler neck-closing position.This informs the cap installer that continued rotation of outer handle16 in cap-advancing (clockwise) direction is not necessary. However, inillustrative embodiments, it is within the scope of the presentdisclosure to configure cap-installation signaler 11 to generate, insequence, two or more additional discernable warning signals (e.g., WS2in FIGS. 10 and 11 and WS3 in FIGS. 12 and 13) to provide furtherdiscrete alerts to the cap installer that closure 14 has already seatedin filler neck 12 and arrived at the stationary filler neck-closingposition.

In accordance with the present disclosure, a cap designer can customizefiller neck cap 20 at the design stage easily to meet the needs of avehicle manufacturer to establish any desired number of discernablewarning signals that can be produced by a user during rotation of outerhandle 16 from a ready-to-install position to a stationary handlehard-stop position as filler neck cap 20 is installed in filler neck 12.The maximum number of discernable warning signals that can be producedduring a single cap-installation activity is equal to the number oftorque teeth 11T provided by the fuel cap designer in thesignal-generation zone 11Z as suggested in FIG. 5. In the illustratedexample, three torque teeth 11T1, 11T2, and 11T3 are provided insignal-generation zone 11Z. Thus, a series of three discernable warningsignals WS1, WS2, and WS3 can be produced during cap installation assuggested in FIGS. 6-13.

In illustrative embodiments, each of the discernable warning signalsWS1, WS2, and WS3 is generated each time a radially outwardly extendingdrive head 11H carried on an elastic spring arm 11A included in adeflectable closure rotator 11CR of torque-transmission member 18contacts the ramped surface 11TR and then passes over and snaps past oneof the radially inwardly extending torque teeth 11T included in closure14 when a cap installer rotates outer handle 16 in cap-advancing(clockwise) direction 22 about axis of rotation 20 relative to thestationary closure 14 seated in the filler neck-closing position infiller neck 12 as suggested, for example, in FIGS. 8, 10, and 12. Inillustrative embodiments, deflectable closure rotator 11CR oftorque-transmission member 18 and torque teeth 11T of closure 14cooperate to define a cap-installation signaler 11 as suggesteddiagrammatically in FIG. 2.

Filler neck cap 10 includes a closure 14 adapted to close filler neck12, an outer handle 16 arranged to overlie closure 14 and rotaterelative to closure 14, and a torque-transmission member 18 having aperipheral portion 11CR coupled to closure and an inner portion 25coupled to the underside of outer handle 16 to rotate therewith about anaxis of rotation 20 relative to filler neck 12 during installation offiller neck cap 10 in filler neck 12 as suggested in FIGS. 1-3. Duringcap installation, a cap installer inserts base 14B of closure 14 offiller neck cap 10 into fuel-conducting passageway 12P as suggested inFIG. 1 to cause a thread 14T on base 14B of closure 14 to engage acompanion thread 12T formed in filler neck 12 so that closure 14 can berotated about axis of rotation 20 until it assumes a filler-neck closing(hard stop) position established, for example, by engagement ofrotation-inhibitor tab 15T in closure 14 and anti-rotation stop 15Scoupled to filler neck 12.

Once closure 14 engages filler neck 12, the cap installer rotates outerhandle 16 in cap-advancing (clockwise) direction 22 about axis ofrotation 20 to cause torque-transmission member 18 to rotate about axisof rotation 20 to cause closure rotator 11CR to apply arotation-inducing torque to the inclined ramp surface 11TR of one of thetorque teeth 11T included in a torque receiver 110 provided in closure14 while closure 14 is engaged to filler neck 12 as suggested in FIGS. 6and 7. Closure 14 is then rotated about axis of rotation 20 until arotation-inhibitor tab 15T included in a closure-rotation blocker 15 andcoupled to closure 14 mates with a stationary anti-rotation stop 15Salso included in closure-rotation blocker 15 and coupled to filler neck12 as suggested in FIG. 1. Engagement of rotation-inhibitor tab 15T andanti-rotation stop 15S provides a HARD STOP to establish the stationaryclosure hard-stop position of closure 14 in filler neck 12 so thatclosure 14 is not able to rotate further in fuel-conducting passageway12P relative to filler neck 12 in response to continued rotation by acap installer of outer handle 16 and torque-transmission member 18 incap-advancing (clockwise) direction 22. Closure 14 has now arrived at astationary filler-neck closing position and an O-ring seal 39 coupled toclosure 14 as suggested in FIGS. 3 and 4 is trapped between closure 14and filler neck 12.

Further rotation of closure 14 in cap-advancing (clockwise) direction 22stops (i.e., a hard stop) once closure 14 has arrived at the filler-neckclosing position in filler neck 12 as suggested in FIG. 6. However,outer handle 16 is free to be rotated further by the cap installerrelative to the stationary closure 14 through a small angle to actuatecap-installation signaler 11 to produce one or more discernable warningsignals (represented by THUNDERBOLT SYMBOLS WS1, WS2, and WS3) assuggested in FIGS. 8-13. Upon sensing the discernable warning signal,the cap installer will understand that closure 14 has already arrived atthe filler-neck closing position and ceased to rotate further relativeto filler neck 12, filler neck cap 10 has been installed properly, andthat the cap installer can ungrip outer handle 16. A cap installerreceiving one or more of the discernable warning signals WS1, WS2, WS3in accordance with the present disclosure will understand that continuedrotation of outer handle 16 in cap-advancing (clockwise) direction 22(though possible) is not needed. In illustrative embodiments, second andthird (or any selected number of) discernable warning signals WS2, WS3are provided in accordance with the present disclosure in case one ormore signals is overlooked by the cap installer.

Handle-rotation blocker 17 operates to block further rotation of outerhandle 16 about axis of rotation 20 relative to closure 14 after each ofthe discernable warning signals WS1, WS2, and WS3 has been produced.Rotation-inhibitor tab 17T1 included in outer handle 16 engagesanti-rotation stop 17S1 included in closure 14 to establish thestationary handle hard-stop position of outer handle 16 and blockfurther rotation of outer handle 16 about axis of rotation 20 relativeto closure 14 in the cap-advancing (clockwise) direction 27.

Outer handle 16 is gripped by a cap installer and rotated about an axisof rotation 20 in a cap-advancing (clockwise) direction 22 to causeclosure 14 to rotate about axis of rotation 20 until closure 14 reachesa filler-neck closing position in fuel tank filler neck 12. Once closure14 has reached the filler-neck closing position, outer handle 16 can berotated a bit more in cap-advancing (clockwise) direction 22 until aradially outwardly extending drive head 11H appended to an elasticspring arm 11A in deflectable closure rotator 11CR included intorque-transmission member 18 contacts and then passes over and snapspast one or more radially inwardly extending torque teeth 11T includedin signal-generation zone 11Z provided in closure 14 to produce adiscernable warning signal (e.g., an audible clicking sound and/or atactile sensation). The radial design of closure rotator 11CR and torqueteeth 11T cooperate to minimize variation in torque magnitude andenhance flexibility in adjusting click audible and physical warningsignal magnitude and tone to a cap installer. Audible (click) andtactile warning signals (snap of closure rotator 11CR past torque tooth11T and/or hard stop of handle 16) are provided to the cap installerwhen filler neck cap 10 is installed in filler neck 12.Torque-transmission member 18 includes four closure rotators 11CR, 11CR,11CR, and 11CR as shown, for example, in FIG. 2A.

As suggested in FIG. 2, filler neck cap 10 includes outer handle 16, ahandle tether unit 30, a torsion spring 34, toque-transmission member18, torsion spring retainer 36 included in closure 14, pressure-reliefsystem 37, vacuum-relief system 38, a base 14B included in closure 14,and an O-ring seal 39. Torsion spring retainer 36 is configured to matewith base 14B to contain pressure-relief and vacuum-relief systems 37,38 in a chamber 14C formed in base 14B of closure 14 as suggested inFIGS. 3 and 4. Pressure-relief system 37 includes a cover plate 371, apressure-relief spring 372, a seal plate 373, and a sealing gasket 374in an illustrative embodiment. Vacuum-relief system 38 includes avacuum-relief valve 381 and a vacuum-relief spring 382 in anillustrative embodiment.

Handle tether unit 30 includes a tether ring 31 and a tether strap 32coupled to tether ring 31. Tether ring 31 is coupled to outer handle 16as suggested in FIGS. 2 and 3. Outer handle 16 and tether unit 30 mateto form a closure cover 100 as suggested in FIG. 3 that is configured tocover closure 14 as suggested in FIGS. 1 and 4.

Outer handle 16 is formed to include a small ring of radially inwardlyextending torque teeth 16T visible on the underside of outer handle 16as suggested in FIG. 3. Outer handle 16 also includes an upper springmount 16M configured to mate with an upper tang 341 of torsion spring 34as suggested in FIGS. 1 and 3. The ring of torque teeth 16T is arrangedto surround upper spring mount 16M. Each torque tooth 16T has aninclined ramp surface and a vertical flat surface as suggested in FIG.3.

Base 14B of closure 14 includes a torque receiver 110 defined by arelatively larger ring of radially inwardly torque teeth 11T as shown,for example, in FIG. 3. Torque spring retainer 36 is mounted in a centerportion of base 14B of closure 14 so as to be surrounded by the ring oftorque teeth 11T as shown in FIG. 3. Torque spring retainer 36 includesa web 361 coupled to closure 14 and an upwardly extending post 362coupled to web 361 and formed to include a lower spring mount 36Mconfigured to mate with a lower tang 342 of torsion spring 34 assuggested in FIGS. 1 and 3. Torsion spring 34 includes a coil 343arranged to interconnect upper and lower tangs 341, 342 as suggested inFIGS. 1-4.

Ratchet arms 25 and 25 included in torque-transmission member 18 areconfigured to mate with torque teeth 16T included in outer handle 16 toallow outer handle 16 to engage torque-transmission member 18 and locktorque-transmission member 18 to outer handle 16 to provide means fortransferring torque applied by the cap installer from outer handle 16 totorque-transmission member 18 so that torque-transmission member 18rotates (at the proper time) in response to rotation of outer handle 16.Ratchet arms 25, 25 cooperate to allow outer handle 16 to be resetautomatically in relation to closure 14 to the ready-to-install positionusing torsion spring 34 so that torque teeth 11T1, 11T2, and 11T3 areprovided once again in signal-generation zone 11Z to be engaged bydeflectable closure rotator 11CR to apply torque to closure 14 viatorque-transmission member 18 and to produce a discernable warningsignal.

Each ratchet arm 25, 25 of torque-transmission member 18 includes aradially outwardly extending drive head 25H coupled to a curved elasticspring arm 25A that is cantilevered to an arm support 25S coupled tocentral hub 18H of torque-transmission member 18 as shown, for example,in FIG. 2A. Each drive head 25H is configured and arranged to engage theinclined ramp surfaces on torque teeth 16T during cap installation andthe vertical flat surfaces on torque teeth 16T during cap removal. In anillustrative embodiment, companion curved elastic spring arm 25A, armsupport 25S, and a curved inner wall 18W of central hub 18H cooperate toform a curved tooth-receiving channel 18C as suggested in FIG. 2A sizedto receive torque teeth 16T of outer handle 16 therein when outer handle16 is mated to torque-transmission member 18 as suggested in FIGS. 3 and5.

After closure 14 reaches the filler-neck closing position (hard stop) infiller neck 12, the deflectable closure rotator 11CR is deflected toprovide a torque-override function and generate a discernable warningsignal such as a clicking sound. In addition to the torque transferbetween outer handle 16 and torque-transmission member 18, ratchet arms25, 25 in torque-transmission member 18 allow handle 16 to engagetorque-transmission member 18 and to reset outer handle 16 (and itsrotation-inhibitor tab 17T1) to its original location relative toclosure 14 to allow cap 10 to be clicked again or removed. Reset actionin accordance with the present disclosure can be manual or automated(use of torsion or other wound spring).

Filler neck cap 10 includes a closure 14 configured to mate with fillerneck 12 and close an inlet aperture 12A opening into a fuel-conductingpassageway 12P formed in filler neck 12 as suggested in FIGS. 1 and 2.Filler neck cap 10 also includes a rotatable outer handle 16 and atorque-transmission member 18 arranged to lie under handle 16 and rotatein a cap-advancing (clockwise) direction 22 with handle 16 duringinstallation of filler neck cap 10 in filler neck 12.

Torque-transmission member 18 is configured to include a hub 18H and adeflectable closure rotator 11CR cantilevered to hub 18H and arranged toengage torque teeth 11T included in closure 16 normally to transmittorque from torque-transmission member 18 to closure 14 duringinstallation of cap 10 in filler neck 12 to cause closure 14 to rotatein filler neck 12 in response to rotation of outer handle 16 relative tofiller neck 12. After closure 14 has arrived at a stationary filler-neckclosing position and during rotation of outer handle 16 relative to thestationary closure 14 in the latter stage of a cap-installationactivity, head 11H of deflectable closure rotator 11CR is moved over andpast each of the radially inwardly extending torque teeth 11T to producethe discernable warning signal WS1, WS2, and WS3. In an illustrativeembodiment, a clicking sound and tactile sensation is provided each timethe head is moved over and past one of torque teeth 11T.

Deflectable closure rotator 11CR is configured to engage the inclinedramp 11TR of one of torque teeth 11T included in closure 14 to transmittorque from outer handle 16 to closure 14 as outer handle 16 is rotatedabout axis of rotation 20 relative to filler neck 12 during installationof filler neck cap 10 in fuel tank filler neck 12. If the cap installercontinues to apply a rotation-inducing torque to handle 16 incap-advancing (clockwise) direction 22 after closure 14 arrives at afiller-neck closing position in filler neck 12 and stops rotating due toengagement of a rotation-inhibitor tab 15T coupled to closure 14 with ananti-rotation stop 15S coupled to filler neck 12 to provide a HARD STOP,then deflectable closure rotator 11CR is moved radially inwardlyrelative to hub 18H from a torque-transmission position to a deflectedposition due to camming engagement of deflectable closure rotator 11CRon an inclined ramp 11TR provided on torque tooth 11T so thatrotation-inducing torque is no longer transmitted from the rotatingtorque-transmission member 18 and its deflectable closure rotator 11CRto closure 14. Thus, transmission of torque from torque-transmissionmember 18 to closure 14 is stopped once closure 14 reaches a stationaryfiller-neck closing position in filler neck 12 due to the torque-limitedengagement of deflectable closure rotator 11CR and torque teeth 11T inclosure 14 even though a cap installer may continue to rotate outerhandle 16 and torque-transmission member 18 together (as a unit) aboutaxis of rotation 20 relative to closure 14 and filler neck 12 incap-advancing (clockwise) direction 22.

Deflectable closure rotor 11CR and torque teeth 11T included in fillerneck cap 10 cooperate during installation of cap 10 in filler neck 12 toproduce a discernable warning signal (e.g., audible sound and/or tactilesensation) to alert a cap installer turning cap 10 in a cap-advancing(clockwise) direction 22 in filler neck 12 that closure 14 has stoppedrotating and seated in a filler-neck closing position in filler neck 12.Inclined ramps 11TR on one or more radially inwardly extending torqueteeth 11T included in closure 14 are arranged to intercept and cooperatewith a radially outwardly extending head 11H coupled to an elasticspring arm 11A included in deflectable closure rotator 11CR oftorque-transmission member 18 first to transmit torque fromtorque-transmission member 18 to closure 14 during rotation of closure14 in filler neck 12 and then to provide the discernable warning signalonce closure 14 arrives at the stationary filler neck 12. The radiallyoutwardly extending head of deflectable closure rotator 11CR is movedover and past each of the stationary radially inwardly extending torqueteeth 11T during rotation of handle 16 and torque-transmission member 18in cap-advancing (clockwise) direction 22 relative to the stationaryclosure 14 to produce a discernable warning signal to alert a capinstaller that closure 14 has already arrived at the filler-neck closingposition in filler neck 12 and that it is no longer necessary tocontinue to rotate handle 16 in cap-advancing (clockwise) direction 22.

Filler neck cap 10 further includes a handle-rotation blocker 17including an anti-rotation stop 17S1 coupled to closure 14 to rotatetherewith and a rotation-inhibitor tab 17T1 coupled to outer handle 16to rotate therewith. During the latter stages of a cap-installationactivity after one or more discernable warning signals have beengenerated, the rotation-inhibitor tab 17T1 can be moved toward and matedwith the anti-rotation stop 17S1 during continued rotation of outerhandle 16 and torque-transmission member 18 relative to stationaryclosure 14 to block further rotation of outer handle 16 in thecap-advancing (clockwise) direction 22 relative to closure 14 andprovide a HARD STOP for outer handle 16.

In use, rotation-inhibitor tab 17T1 coupled to outer handle 16 is alwaysarranged to lie in circumferentially spaced-apart relation toanti-rotation stop 17S1 that is coupled to closure 14 when closure 14arrives and stops at the filler-neck closing position in filler neck 12.Even though rotation of closure 14 in filler neck 12 has stopped, thecap installer is free to continue to rotate outer handle 16 about theaxis of rotation 20 relative to the stationary closure 14 to produce oneor more discernable warning signals WS1, WS2, WS3 untilrotation-inhibitor tab 17T1 on outer handle 16 is moved relative tostationary closure 14 along a curved path to mate with anti-rotationstop 17S1 on closure 14 so that further rotation of outer handle 16about axis of rotation 20 relative to closure 14 is blocked.

By selecting the number of torque teeth 11T and establishing the lengthof the curved path traveled by rotation-inhibitor tab 17T1 coupled toouter handle 16 until it mates with anti-rotation stop 17S1 coupled tothe stationary closure 14 during the design of a filler neck cap 10 inaccordance with the present disclosure, it is possible for a fuel capdesigner to create one, two, three, or more clicks or other discernablewarning signals (WS) to alert the cap installer that closure 14 hasarrived at the filler-neck closing position in filler neck 12 and thatit is no longer necessary to continue to rotate outer handle 16 (andtorque-transmission member 18) in cap-advancing (clockwise) direction22. Mating engagement of rotation-inhibitor tab 17T 1 and anti-rotationstop 17S1 provides a HARD STOP for outer handle 16 to block furtherrotation of outer handle 16 about axis of rotation 20 relative to thestationary closure 14 in cap-advancing (clockwise) direction 22 in casethe cap installer ignores the discernable warning signal (WS) providedby the operation of the cap-installation signaler 11 defined bydeflectable closure rotator 11CR and companion radially inwardlyextending torque teeth 11T.

A series of views of filler neck cap 10 during removal of filler neckcap 10 from filler neck 12 is shown, for example, in FIGS. 14-19. Assuggested in FIG. 14, a counterclockwise torque has been applied toouter handle 16 to urge direction 23 to cause a flat driver face on head17H of deflectable closure rotator 11CR to mate with companion flatdriven face on the third torque tooth 11T to prepare closure 14 to berotated in a cap-removal (counterclockwise) direction 23 relative tofiller neck 12 during a process of removing filler neck cap 10 fromfiller neck 10. As suggested in FIG. 16, closure 14 is turning in fillerneck 12 in response to rotation of outer handle 16 in the cap-removal(counterclockwise) direction 23 and application of a rotation-inducingtorque from the deflectable closure rotators 11CR to torque teeth 11T oftorque receiver 110 in closure 14. FIG. 18 is a top plan view similar toFIG. 16 after the filler neck cap has been removed from the filler neck.FIG. 19 is a view similar to FIG. 18 with most of outer handle 16removed and showing that torsion spring 34 (that had been loaded duringthe cap-installation process) was freed and able to unload as soon asfiller neck cap 10 was removed from filler neck 12.

A filler neck cap 10 having a cap-installation management system isprovided for a filler neck 12 as suggested in FIG. 1. Filler neck cap 10includes an outer handle 16 rotatable about an axis of rotation 20 and aclosure 14 including a base 14B adapted to close filler neck 12 and atorque receiver 10 coupled to base 14B and arranged to lie inspaced-apart relation to axis of rotation 20 as suggested in FIGS. 1 and2. Torque receiver 110 includes several torque teeth 11T as suggested inFIGS. 1 and 3.

Filler neck cap 10 further includes a torque-transmission member 18rotatable about axis of rotation 20 as suggested in FIGS. 5-19.Torque-transmission member 18 is positioned to lie between outer handle16 and closure 14 and coupled to outer handle 16 to rotate therewithduring rotation of outer handle 16 about axis of rotation 20 in acap-advancing direction 22 as suggested in FIGS. 6-13.Torque-transmission member 18 includes a central hub 18H surroundingaxis of rotation 20 and a deflectable closure rotator 11CR arranged toengage torque teeth 11T included in torque receiver 110 to transmittorque from torque-transmission member 18 to closure 14 duringinstallation of base 14B of closure 14 in filler neck 12 to cause base14B to rotate in filler neck 12 in response to rotation of outer handle16 in cap-advancing direction 22 relative to filler neck 12.

Filler neck cap 10 also includes handle-rotation travel limiter 13including a closure-rotation inhibitor tab 15T, a handle-rotationblocker 17, and a handle-reset system 19 in an illustrative embodimentas suggested in FIGS. 2 and 3. Handle-rotation travel limiter 13 isconfigured to provide means for producing a predetermined number ofseparate discernable warning signals (WS) generated by engagement andsubsequent disengagement of deflectable closure rotator 11CR and torqueteeth 11T included in torque receiver 110 of closure 14 after base 14Bof closure 14 is rotated about axis of rotation 20 in cap-advancingdirection 22 to reach a closure hard-stop position (FIGS. 6 and 7) infiller neck 12 and cease further rotation in cap-advancing direction 22and before outer handle 16 is rotated from an initial position (FIGS.5-7) about axis of rotation 20 in cap-advancing direction 22 relative toclosure 14 in the closure hard-stop position (FIGS. 6 and 7) to reach ahandle hard-stop position (FIGS. 12 and 13) and cease further rotationin cap-advancing position 22 relative to closure 14 so that continuedrotation of outer handle 16 about axis of rotation 20 in cap-advancingdirection 22 after closure 14 has reached the closure hard-stop position(FIGS. 6 and 7) causes at most the predetermined number of separatediscernable warning signals (WS) to be produced before outer handle 16is rotated about axis of rotation 20 in cap-advancing direction 22relative to base 14B of closure 14 to reach the handle hard-stopposition (FIGS. 12 and 13).

Handle-rotation travel-limit means 13 includes an anti-rotation stop17S1 coupled to closure 14 to rotate therewith and a rotation-inhibitortab 17T1 coupled to outer handle 16 to rotate therewith and to engageanti-rotation stop 17S1 to block further rotation of outer handle 16 incap-advancing direction 22 relative to closure 14 that is stationary inthe closure hard-stop position (FIGS. 6 and 7) when outer handle 16reaches handle hard-stop position (FIGS. 12 and 13). Anti-rotation stop17S1 is arranged to lie in spaced-apart relation to torque-transmissionmember 18 to locate a portion of torque receiver 110 therebetween assuggested in FIG. 5. Torque receiver 110 is arc-shaped as suggested inFIG. 5 and includes a series of circumferentially spaced-apart toothmounts 11M and each torque tooth 11T is coupled to a pair of adjacenttooth mounts 11M and arranged to extend radially inwardly toward axis ofrotation 20 to engage deflectable closure rotator 11CR during rotationof torque-transmission member 18 about axis of rotation 20 relative toclosure 14. Anti-rotation stop 17S1 is coupled to one of the toothmounts 11M as suggested in FIG. 5.

Base 14B of closure 14 includes a barrel 14B1 arranged to extend axiallyalong axis of rotation 20 and an annular plate 14B2 coupled to an upperend of barrel 14B1 and arranged to lie in a position between barrel 14B1and a top wall 161 of outer handle 16 as suggested in FIGS. 1, 4, and 6.Torque receiver 110 is coupled to an upwardly facing surface of annularplate 14B2 and arranged to extend upwardly away from barrel 14B1 and tosurround torque-transmission member 18 as suggested in FIGS. 1 and 2.Each torque tooth 11T is arranged to extend in a radially inwarddirection toward axis of rotation 20 as suggested in FIG. 5.

Anti-rotation stop 17S1 of handle rotation blocker 17 is coupled to theupwardly facing surface of annular late 14B2 as suggested in FIGS. 3 and5. Anti-rotation stop 17S1 is also coupled to one of torque teeth 11Tand arranged to extend in a radially outward direction away from axis ofrotation 20. Outer handle 16 includes a top wall 161 arranged to overlietorque-transmission member 18 and a side wall 162 coupled to aperipheral portion of top wall 161 and arranged to surround a perimeteredge of top plate 14B2 to locate anti-rotation stop 17S1 in a spaceprovided between torque receiver 110 and side wall 162 of outer handle16. Rotation-inhibitor tab 17T1 is coupled to side wall 162 to extend ina radially inward direction toward axis of rotation 20 and is arrangedto mate with anti-rotation stop 1751 in response to rotation of outerhandle 16 to the handle hard-stop position (FIGS. 12 and 13) when base14B of closure 14 is in the closure hard-stop position (FIGS. 6 and 7).

A torque tooth 11T (e.g., three tongue teeth 11T1-3) included in torquereceiver 110 is positioned to lie between rotation-inhibitor tab 17T1and torque-transmission member 18 once outer handle 16 is rotated toreach the handle hard-stop position (FIGS. 12 and 13). Anti-rotationstop 17S1 is positioned to lie between torque receiver 110 and side wall162 of outer handle 16.

Handle-rotation travel limiter 13 further includes handle-reset means 19for automatically rotating closure 14 about axis of rotation 20 relativeto outer handle 16 in a cap-removal direction 22 opposite tocap-advancing direction 23 while a user is gripping outer handle 16 assoon as base 14B of closure 14 is separated from filler neck 12 during acap-removal activity to move rotation-inhibitor tab 17T1 to aready-to-install initial position (FIGS. 6 and 7) and establish apredetermined arcuate distance between the anti-rotation stop 1751coupled to closure 14 and rotation-inhibitor tab 17T1 to cause a numberof torque teeth 11T included in torque receiver 110 that is equal to thepredetermined number of separate discernable warning signals (WS) to liein a signal-generation zone 11Z provided between anti-rotation stop17S1, rotation-inhibitor tab, and axis of rotation 20 so thatdeflectable closure rotator 11CR will engage and subsequently disengagesaid number of torque teeth 11T during movement of rotation-inhibitortab 17T1 relative to base 14B of closure 14 from the initial position(FIGS. 6 and 7) to the handle hard-stop position (FIGS. 12 and 13).

Handle-reset means 19 includes a torsion spring 34 including an uppertang 341 coupled to outer handle 16, a lower tang 343 coupled to closure14, and a coil 342 arranged to wind around axis of rotation 20 tointerconnect upper and lower tanks 341, 343. Closure 14 includes atorsion spring retainer 36 coupled to base 14B to form a chamber 14Ctherebetween. A pressure-relief system 37 and a vacuum-relief system 38also included in filler neck cap 10 is located in chamber 14C. Torsionspring retainer 36 includes a web 361 coupled to base 14B to definechamber 14C therebetween and an upwardly extending post 362 coupled toweb 361. Upwardly extending post 362 is arranged to extend upwardly awayfrom web 361 along axis of rotation 20 through a central aperture 18Aformed in torque-transmission member 18 to mate with lower tang 343 oftorsion spring 34.

Outer handle 16 further includes a hollow hand grip 16G coupled to topwall 161 at an opening formed in top wall 161 and arranged to extendupwardly away from base 14B as suggested in FIGS. 1 and 4. Torsionspring 34 is located in a hollow chamber 16C formed in hollow hand grip16G as suggested in FIGS. 1 and 4.

Handle-rotation travel limiter 13 further includes a handle-locator stopand a handle-locator tab 19T as suggested in FIG. 5. Handle-locator stop19S is coupled to closure 14 and arranged to lie in spaced-apartrelation to anti-rotation stop 17S1 to define a tab-travel zone TTZtherebetween as suggested in FIG. 7. Rotation-inhibitor andhandle-locator tabs 17T1, 19T are coupled to side wall 162 and arrangedto extend radially inwardly toward axis of rotation 20.Rotation-inhibitor tab 17T1 is positioned to lie and move in tab-travelzone (TTZ) relative to closure 14 during rotation of outer handle 16about axis of rotation 20 from the initial position (FIGS. 6 and 7) tothe handle hard-stop position (FIGS. 12 and 13). Handle-locator tab 19Tis coupled to outer handle 16 to move therewith and positioned to lie intab-travel zone (TTZ) between rotation-inhibitor tab 17T1 andhandle-locator stop 19T. Handle-locator tab 19T is arranged to engagehandle-locator stop 19S coupled to closure 14 during automatic rotationof closure 14 about axis of rotation 20 relative to outer handle 16 incap-removal direction 23 to establish the initial position (FIGS. 6 and7) of rotation-inhibitor tab 17S1. Handle-rotation travel limiter means13 further includes at least one stiffener tab 19ST coupled to outerhousing 16 to rotate therewith and located between and in spaced-apartrelation to each of the rotation-inhibitor and handle-locator tabs 17T1,19T to provide means for rigidifying outer handle 16.

Torsion spring 34 is configured to provide handle-reset means forautomatically rotating closure 14 about axis of rotation 20 relative toouter handle 16 in a cap-removal direction 23 opposite to cap-advancingdirection 22 while a user is gripping outer handle 16 as soon as base14B of closure 14 is separated from filler neck 12 during a cap-removalactivity to cause handle-locator stop 19S to move to engagehandle-locator tab 19T to block further rotation of closure 14 relativeto outer handle 16 to establish a ready-to-install position of closure14 relative to outer handle 16 in cap-advancing direction 22 to reachthe closure hard-stop position (FIGS. 6 and 7) in filler neck 12 andbefore outer handle 16 is rotated about axis of rotation 20 incap-advancing position 20 to reach the handle hard-stop position (FIGS.12 and 13). Torque receiver 110 includes three torque teeth arranged tobe engaged in sequence by deflectable closure rotator 11CR to produce insequence three separate discernable warning signals WS1, WS2, WS3 duringrotation of outer handle 16 relative to closure 14 from the initialposition (FIGS. 6 and 7) to the handle hard-stop position (FIGS. 12 and13).

Closure 14 further includes a closure-rotation inhibitor tab 15T coupledto base 14B to rotate therewith relative to filler neck 12. Closurerotation inhibitor tab 15T is configured to provide means for engagingan anti-rotation stop 15S included in filler neck 12 upon arrival ofbase 14B of closure 14 at the closure hard-stop position (FIGS. 6 and 7)in filler neck 12 so that further rotation of base 14B about axis ofrotation 20 relative to filler neck 12 is blocked during continuedrotation of outer handle 16 about axis of rotation in cap-advancingdirection 22.

Central hub 18H of torque-transmission member 18 is formed to include acentral aperture 18A through which axis of rotation 20 extends assuggested in FIG. 2. Outer handle 16 includes a ring 110 of radiallyinwardly extending torque teeth 11T. Torque-transmission member 18further includes a ratchet arm 25 cantilevered at one end thereof tocentral hub 18H and located in the central aperture 18A formed incentral hub 18H to mate with ring 110 of radially inwardly extendingtorque teeth 11T to provide means for transferring torque applied by acap installer to outer handle 16 to torque-transmission member 18 sothat torque-transmission member 18 rotates relative to outer handle 16during a cap-installation activity. Ratchet arm 25 is configured to slipand move relative to ring 10 of radially inwardly extending torque teeth11T without transferring torque between outer handle 16 andtorque-transmission member 18 during automatic rotation of closure 14about axis of rotation 20 relative to outer handle 16 in cap-removaldirection 23 in response to torque applied to closure 14 by torsionspring 34 of handle-reset system 19.

The invention claimed is:
 1. A filler neck cap having a cap-installationmanagement system for a filler neck, the system comprising an outerhandle rotatable about an axis of rotation, a closure including a baseadapted to close the filler neck and a torque receiver coupled to thebase and arranged to lie in spaced-apart relation to the axis ofrotation, the torque receiver including several torque teeth, atorque-transmission member rotatable about the axis of rotation, thetorque-transmission member being positioned to lie between the outerhandle and the closure and coupled to the outer handle to rotatetherewith during rotation of the outer handle about the axis of rotationin a cap-advancing direction, the torque-transmission member including acentral hub surrounding the axis of rotation and a deflectable closurerotator arranged to engage the torque teeth included in the torquereceiver to transmit torque from the torque-transmission member to theclosure during installation of the base of the closure in the fillerneck to cause the base to rotate in the filler neck in response torotation of the outer handle in the cap-advancing direction relative tothe filler neck, and handle-rotation travel-limit means for producing apredetermined number of separate discernable warning signals generatedby engagement and subsequent disengagement of the deflectable closurerotator and torque teeth included in the torque receiver of the closureafter the base of closure is rotated about the axis of rotation in thecap-advancing direction to reach a closure hard-stop position in thefiller neck and cease further rotation in the cap-advancing directionand before the outer handle is rotated from an initial position aboutthe axis of rotation in the cap-advancing direction relative to theclosure in the closure hard-stop position to reach a handle hard-stopposition and cease further rotation in the cap-advancing positionrelative to the closure so that continued rotation of the outer handleabout the axis of rotation in the cap-advancing direction after theclosure has reached the closure hard-stop position causes at most thepredetermined number of separate discernable warning signals to beproduced before the outer handle is rotated about the axis of rotationin the cap-advancing direction relative to the base of the closure toreach the handle hard-stop position, wherein the handle-rotationtravel-limit means includes an anti-rotation stop coupled to the closureto rotate therewith and a rotation-inhibitor tab coupled to the outerhandle to rotate therewith and to engage the anti-rotation stop to blockfurther rotation of the outer handle in the cap-advancing directionrelative to the closure that is stationary in the closure hard-stopposition when the outer handle reaches the handle hard-stop position,and wherein the handle-rotation travel-limit means further includeshandle-reset means for automatically rotating the closure about the axisof rotation relative to the outer handle in a cap-removal directionopposite to the cap-advancing direction while a user is gripping theouter handle as soon as the base of the closure is separated from thefiller neck during a cap-removal activity to move the rotation-inhibitortab to an initial position and establish a predetermined arcuatedistance between the anti-rotation stop coupled to the closure and therotation-inhibitor tab to cause a number of torque teeth included in thetorque receiver that is equal to the predetermined number of separatediscernable warning signals to lie in a signal-generation zone providedbetween the anti-rotation stop, the rotation-inhibitor tab, and the axisof rotation so that the deflectable closure rotator will engage andsubsequently disengage said number of torque teeth during movement ofthe rotation-inhibitor tab relative to the base of the closure from theinitial position to the handle hard-stop position.
 2. The filler neckcap of claim 1, wherein the handle-reset means includes a torsion springincluding an upper tang coupled to the outer handle, a lower tangcoupled to the closure, and a coil arranged to wind around the axis ofrotation to interconnect the upper and lower tangs.
 3. The filler neckcap of claim 2, wherein the closure includes a torsion spring retainercoupled to the base to form a chamber therebetween and furthercomprising a pressure-relief system and a vacuum-relief system locatedin the chamber.
 4. The filler neck cap of claim 3, wherein the torsionspring retainer includes a web coupled to the base to define the chambertherebetween and an upwardly extending post coupled to the web andarranged to extend upwardly away from the web along the axis of rotationthrough a central aperture formed in the torque-transmission member tomate with the lower tang of the torsion spring.
 5. The filler neck capof claim 2, wherein the outer handle includes a top wall arranged tooverlie the torque-transmission member and a side wall arranged toextend downwardly from a peripheral portion of the top wall to surroundan upper portion of the base and the anti-rotation stop, therotation-inhibitor tab is coupled to the side wall of the outer handleto extend radially inwardly toward the axis of rotation, and the outerhandle further includes a hollow hand grip coupled to the top wall at anopening formed in the top wall and arranged to extend upwardly away fromthe base, and the torsion spring is located in a hollow chamber formedin the hollow hand grip.
 6. The filler neck cap of claim 5, wherein atorque tooth included in the torque receiver is positioned to liebetween the rotation-inhibitor tab and the torque-transmission memberonce the outer handle is rotated to reach the handle hard-stop position.7. The filler neck cap of claim 5, wherein the anti-rotation stop ispositioned to lie between the torque receiver and the side wall of theouter handle.
 8. The filler neck cap of claim 1, wherein thehandle-rotation travel-limit means further includes a handle-locatorstop coupled to the closure and arranged to lie in spaced-apart relationto the anti-rotation stop to define a tab-travel zone therebetween, therotation-inhibitor tab is positioned to lie and move in the tab-travelzone relative to the closure during rotation of the outer handle aboutthe axis of rotation from the initial position to the handle hard-stopposition, and the handle-rotation travel-limit means further includes ahandle-locator tab coupled to the outer handle to move therewith andpositioned to lie in the tab-travel zone between the rotation-inhibitortab and the handle-locator stop, and the handle-locator tab is arrangedto engage the handle-locator stop coupled to the closure duringautomatic rotation of the closure about the axis of rotation relative tothe outer handle in the cap-removal direction to establish the initialposition of the rotation-inhibitor tab.
 9. The filler neck cap of claim8, wherein the handle-rotation travel-limit means further includes atleast one stiffener tab coupled to the outer housing to rotate therewithand located between and in spaced-apart relation to each of therotation-inhibitor and handle-locator tabs to provide means forrigidifying the outer handle.
 10. The filler neck cap of claim 8,wherein the handle includes a top wall arranged to overlie thetorque-transmission member and a side wall coupled to a peripheralportion of the top wall and arranged to surround an upper portion of thebase of the closure and the rotation-inhibitor and handle-locator tabsare coupled to the side wall and arranged to extend radially inwardlytoward the axis of rotation.